Mark Hutcheon Email & Phone Number

The Woodlands, Tx, Us

I provide process technology support for all of Huntsman’s maleic anhydride plants and licensees, including reactor catalyst packing technology and performance, back-end product purification, reliability analysis, process safety scenario analysis and more. I initiate and support CAPEX projects, sometimes leading FMEA’s on major equipment in mature plants. I lead benchmarking efforts and best-practice sharing amongst all Maleic sites to foster safety and operational optimal consistency. I develop operating budgets and production plans.

Easley, Sc, Us

I held Project Manager and Lead Process Engineer roles during the design effort to expand the company into a new world-class domestic site in support of it's rapid growth. My major contributions consisted of preparing the initial estimate (teaming with an Architectural & Engineering firm), converting a major process from batch to continuous (saving capital and streamlining operations), and reducing other unnecessary design features which saved a total of 36% of the overall project cost (of magnitude ~$50 million).

Allentown, Pennsylvania, Us

I managed and influenced all facets of a $60 million, developmental, government-funded (U.S. Dept. of Energy - DOE), novel technology oxygen-separation and power-generation test plant from construction through start-up. The plant delivered first-ever tonnage oxygen production (an extreme feat) by employing ion transport ceramic membranes (ITMs) and generated data for commercial plant design and operation. My key responsibilities and accomplishments were:- Manage stakeholder priorities: Balanced Project Engineering, ITM R&D Engineering, and Operations needs to achieve Company and DOE goals.- Commission and start-up plant safely while meeting DOE-contract goals: I created and executed commissioning plans involving 20+ mechanical/electrical/controls engineers and field technicians. I met DOE timing constraints for an incident-free start-up, and recognized and solved several safety and engineering challenges associated with equipment unique to ITM process.- Operate the plant to produce oxygen and power through use of ITM technology: I streamlined operating philosophy, and devised innovative process control improvements for robust, reliable tonnage oxygen/power production. I mentored and managed a 12-member staff over multiple runs, and I improved campaign turnaround time and cost by 35%.- Become the Company expert in starting up ITM plants: I achieved mastery in operation and maintenance of large compressors, gas burners generating wide-ranging flue gas temperatures (300-1800°F), one-of-a-kind high-temperature heat exchangers (>1600°F), specialty ceramic membranes, steam boilers, and gas-fired turbine/expander/generator.- Supervise the construction: Addressed and organized the resolution of critical engineering and safety issues. I coordinated work for 75 contractors to prepare for staged commissioning sequence.- Develop plant commissioning and operating budgets: Held expenses within DOE-contract budget.

Allentown, Pennsylvania, Us

I led a staff of 10 chemist/technicians to deliver scale-up data and developmental quantities of new specialty chemical and advanced material products. I designed experiments for pilot-scale activities, which led to commercial-scale schemes for products such as: - Higher Borate for Novel Lithium Battery Anion – Scaled-up a 14-step atypical-chemistry process from bench scale to semi-works scale in two years, exceeding targeted yield by 18%, while maintaining product purities. - Specialty Amine Curing Agent – Reduced number of processing steps, and eliminated a hazardous solvent for a strategic product. Transferred technology to plant, and produced 2 MT @ >75% profit margin.- Epoxy Diluents – Demonstrated high-output production by designing and operating a compact two-step continuous reactor train, replacing batch process. Scheme reduced working volume by 100:1, reducing capital and safety exposure on highly exothermic reaction.

Allentown, Pennsylvania, Us

I scaled-up specialty and electronics chemical products and technologies out of R&D into commercial in-house and contractor plants, employing stage gate discipline, all garnering high margins typical of specialty chemicals: - Specialty Surfactant (Hydroxy Acid Esters) – Commercialized line of new products from bench scale involving atypical esterification. Produced initial commercial quantities for new product line at toller.- Molecular Defoamers from Adduction of Alkoxylate – Shepherded commercialization of new defoamer line through pilot scale. Established manufacturing in North America and Europe.- Hydrogenation of Acetylenic – Scaled-up hydrogenation and distillation of acetylenic compound specialty surfactant. Solved significant reaction technical hurdle. Other chemistries with practical plant-scale experience: Acetylenics, alkoxylation, benzylation of amines, epoxy diluents, polyurethanes, and amine curing agents.Other process equipment with practical experience: Batch polymerization, batch reactors, heterogeneous reactors, batch distillation, wiped-film evaporators, drum flakers, filters (including dia-filtration), dryers.

I started-up a multi-unit poly-phenylene oxide monomer/polymer plant, U.S. Gulf Coast, and solved technical issues regarding molecular weight control and catalyst extraction by leveraging the pilot plant in West Virginia.